Wild Dog Adventure Riding

Technical Section => Make / Model Specific Discussions => BMW 650GS / Dakar / XChallenge Singles => Topic started by: Jughead on June 30, 2010, 09:38:00 am

Title: Dakar Swingarm Bearing Mod
Post by: Jughead on June 30, 2010, 09:38:00 am
After the recent bearing fail (http://www.wilddog.za.net/forum/index.php?topic=51673.0) I decided to replace the bearing with Phosphor bronze bushing.  Herewith some pics of the mod.

This is what the bearing looks like after a few too many water crossings and no maintenance.
(http://i47.tinypic.com/32zl26s.jpg)

(http://s6.tinypic.com/14l3p95.jpg)

(http://s6.tinypic.com/2rh72j6.jpg)

New Bushes and inner race
(http://s6.tinypic.com/25a1ac6.jpg)

Old and new
(http://s6.tinypic.com/w6tufm.jpg)

Hole drilled and tapped to accommodate the grease nipple.
(http://s6.tinypic.com/2ypn9xk.jpg)

Grease nipple fitted with dust cap.
(http://s6.tinypic.com/w822xd.jpg)

Fitting the bush
(http://s6.tinypic.com/e9tf5y.jpg)

Unfortunately the right hand side necessitated a hole to be drilled in the end of the chain guide.
(http://s6.tinypic.com/1g42g6.jpg)

Position of the rhs nipple, easily accessible be removing the front sprocket cover.
(http://s6.tinypic.com/2rr1nxg.jpg)

And with it's dust cover.
(http://s6.tinypic.com/311kz1c.jpg)






Title: Re: Dakar Swingarm Bearing Mod
Post by: michnus on June 30, 2010, 09:43:24 am
nogal nifty thanks for sharing.  :thumleft:

btw, it's quite easy to rip the swing-arm out and re grease the races every 20000km, they would last a life time.  ;)
Title: Re: Dakar Swingarm Bearing Mod
Post by: BOER! on June 30, 2010, 09:44:02 am
Excellent.  Good job, and thanks for posting Juggie.  :thumleft:
 Considering doing the same to mine.

Did you buy the bushes standard or had them custom made?   :patch:
Title: Re: Dakar Swingarm Bearing Mod
Post by: Jughead on June 30, 2010, 09:47:07 am
Excellent.  Good job, and thanks for posting Juggie.  :thumleft:
 Considering doing the same to mine.

Did you buy the bushes standard or had them custom made?   :patch:

Bushes were custom made BS, together with the SS inner race.
Title: Re: Dakar Swingarm Bearing Mod
Post by: Battlestar on June 30, 2010, 09:47:42 am
Brilliant

Well done
Title: Re: Dakar Swingarm Bearing Mod
Post by: Jughead on June 30, 2010, 09:57:11 am
nogal nifty thanks for sharing.  :thumleft:

btw, it's quite easy to rip the swing-arm out and re grease the races every 20000km, they would last a life time.  ;)

So i discover Michnus.  I was previously led to believe that the tank had to be removed and the shock strapped up etc, etc.  Major mission!  Now I discover it's only 2 bolts.  ???  Had I known that I would've serviced it more than every 20k

Title: Re: Dakar Swingarm Bearing Mod
Post by: michnus on June 30, 2010, 10:00:03 am
did you get prices from the dealer for the bushes and bearings or can it be bought aftermarket?
Title: Re: Dakar Swingarm Bearing Mod
Post by: Jughead on June 30, 2010, 10:04:22 am
did you get prices from the dealer for the bushes and bearings or can it be bought aftermarket?

http://www.wilddog.za.net/forum/index.php?topic=51673.0

Bearings can be bought anywhere for R50 each.  It's the inner race that's the problem.  None available in the country (what's new!) and a 21day wait to get zem from germany ous.
Title: Re: Dakar Swingarm Bearing Mod
Post by: Bernard Draadkar on June 30, 2010, 07:09:39 pm
Thanks Jughead! I have just done both my forkseals and headset bearings (myself) and this was next on my list. Thanks for the tip Jughead and Michnus of loosening only the two bolts. Also thought I had to take everything apart. (You ous there in PE do the Baviaans water crossing too often I think. Lekker spoilt...)
Title: Re: Dakar Swingarm Bearing Mod
Post by: grego on June 30, 2010, 08:15:38 pm
where did you buy the dust caps for the grease nipples?
Title: Re: Dakar Swingarm Bearing Mod
Post by: Jughead on July 01, 2010, 02:44:43 pm
where did you buy the dust caps for the grease nipples?

Those are actually covers on the brake fluid bleed nipples on many cars.  Just visit your freindly scrapyard and you can pick up handfulls for next to nothing.
Title: Re: Dakar Swingarm Bearing Mod
Post by: Sakkie on July 01, 2010, 02:57:27 pm
Lekka Jughead !   :thumleft:
We should give it a nice test soon - Sunday perhaps old chap?

You still on for tonight?
Title: Re: Dakar Swingarm Bearing Mod
Post by: grego on July 01, 2010, 09:17:10 pm
where did you buy the dust caps for the grease nipples?

Those are actually covers on the brake fluid bleed nipples on many cars.  Just visit your freindly scrapyard and you can pick up handfulls for next to nothing.
lekker... cool idea!
Title: Re: Dakar Swingarm Bearing Mod
Post by: lecap on July 02, 2010, 08:18:16 am
Using stainless for the replacement of the inner race is less than ideal as it does not pair nicely with phosphor bronze in high pressure applications (shows rapid wear from galling).
If you want to use stainless inner races rather use composite bushes like Glycodur F.
If you want to use bronze get hardened and tempered (58-62HRC) carbon steel or tool steel or even better hardened & tempered and plasma nitrided and plasma oxidised for high corosion resistance.
Title: Re: Dakar Swingarm Bearing Mod
Post by: Battlestar on July 02, 2010, 08:37:43 am
Whoa that is a mouth full  :o
Title: Re: Dakar Swingarm Bearing Mod
Post by: michnus on October 26, 2010, 08:13:08 pm
Tell me I can still use these bushes?  :-\  Was a moerse job getting the old bearing sleeves out, had to heat up the swing arm pivots to hell hot and then bliksem them with a 100ton hammer.

The bushes must be chromed for good effect?
Title: Re: Dakar Swingarm Bearing Mod
Post by: the_BOBNOB on October 26, 2010, 08:16:28 pm
jughead your races still holding up ???

i would really like to know how long they last
Title: Re: Dakar Swingarm Bearing Mod
Post by: Welsh on October 26, 2010, 08:46:14 pm
Tell me I can still use these bushes?  :-\  Was a moerse job getting the old bearing sleeves out, had to heat up the swing arm pivots to hell hot and then bliksem them with a 100ton hammer.

The bushes must be chromed for good effect?

In my professional opinion, they look like they have been subjected to overloading due to carrying Hair Bear and hair salon luggage  O0 
Title: Re: Dakar Swingarm Bearing Mod
Post by: michnus on October 26, 2010, 09:17:59 pm
Tell me I can still use these bushes?  :-\  Was a moerse job getting the old bearing sleeves out, had to heat up the swing arm pivots to hell hot and then bliksem them with a 100ton hammer.

The bushes must be chromed for good effect?

In my professional opinion, they look like they have been subjected to overloading due to carrying Hair Bear and hair salon luggage  O0 

hahaha se moer man  :D

what about titanium ones can you make me a set to be here by Friday?  ;)
Title: Re: Dakar Swingarm Bearing Mod
Post by: Jughead on October 28, 2010, 10:17:08 am
Tell me I can still use these bushes?  :-\  Was a moerse job getting the old bearing sleeves out, had to heat up the swing arm pivots to hell hot and then bliksem them with a 100ton hammer.

The bushes must be chromed for good effect?
Those races are MT boet.  New ones only available from Germany at around R260 ea.

jughead your races still holding up ???

i would really like to know how long they last
Have done about 6k kms on the bike with the new SS races.  Checked them 2 weeks ago and they are still 100%.  VERY happy!  :biggrin: :biggrin:
Title: Re: Dakar Swingarm Bearing Mod
Post by: michnus on October 28, 2010, 10:24:50 am
Got new bushes from ACME in JHB Andrew was kind enough to strip a bike for me. Going to use 0-rings as dust seals next to the bushes

Fok weet kannie dink dis nie n wearable item op 650's nie. BMW het nie eens seals nie. Die nuwe 650 wat ek gekoop het is verseker nie gediens soos dit moes gewees het nie, anders sou dit nie so uit gedraai het na 40000km nie.
Title: Re: Dakar Swingarm Bearing Mod
Post by: Jughead on October 28, 2010, 10:25:11 am
Michnus, it should not have been necessary to heat the swingarm.  Any monkey with a press should have been able to remove them for you.  I mean, if I could do mine, anyone can!  :biggrin:  

The new bearings must be pressed in to the correct depth so don't moer them in wif a moerometer.  They need to be recessed 3mm I think.  I made a small cylindrical block with a 3mm protrusion which prevents the bearing being pressed in further.

IMO the grease nipple mod is a must.  I force grease in there regularly and especially if I have been on a ride with water-crossings.  

I am going to be doing Harold's this weekend so if you need more pics, shout.
Title: Re: Dakar Swingarm Bearing Mod
Post by: Jughead on October 28, 2010, 10:27:35 am
Got new bushes from ACME in JHB Andrew was kind enough to strip a bike for me. Going to use 0-rings as dust seals next to the bushes

Fok weet kannie dink dis nie n wearable item op 650's nie. BMW het nie eens seals nie. Die nuwe 650 wat ek gekoop het is verseker nie gediens soos dit moes gewees het nie, anders sou dit nie so uit gedraai het na 40000km nie.

Are you referring to the inner races or bushes like mine?
Title: Re: Dakar Swingarm Bearing Mod
Post by: michnus on October 28, 2010, 10:29:19 am
Pel jy verstaan nie.  :biggrin: The inner races fell out they were rusted to small bits and the bearing housing were rusted tight to the shaft. The manual and f650 also recommend heating to 100degrees. even then I had to moer them quite hard to just get them to loose grip. I do not have a press and the vice had to do to get them out the last couple of cm's.

The 3mm gap is for the seal to sit tight to the bearing but not critical if 5mm just have a bit more dust that might penetrate if not sealing well. You also have to heat it up to 100degrees when fitting the new bearings. They went in like butter with just tapping them in with a 20size socket which fit perfectly in the hole.

Mine is done, will just fit the new bushes on Monday when I get them
Title: Re: Dakar Swingarm Bearing Mod
Post by: michnus on October 28, 2010, 10:29:55 am
Got new bushes from ACME in JHB Andrew was kind enough to strip a bike for me. Going to use 0-rings as dust seals next to the bushes

Fok weet kannie dink dis nie n wearable item op 650's nie. BMW het nie eens seals nie. Die nuwe 650 wat ek gekoop het is verseker nie gediens soos dit moes gewees het nie, anders sou dit nie so uit gedraai het na 40000km nie.

Are you referring to the inner races or bushes like mine?

The bushes, there's only them and the bearings. I am not going to the grease nipple mod, it is easy enough on every 10000km to quickly strip it out and re grease and also to inspect the bearings. with the grease nipple mod it will give you a false sense of security thinking it is always okay and then you get kak.  ;)
Title: Re: Dakar Swingarm Bearing Mod
Post by: Jughead on October 28, 2010, 10:37:12 am
Jy praat nou van die part met die rooi pyltjie?  Dit is die "Inner Race"

Ek het die bearings vervang met bushes, die groen pyltjies.

Ek het ook "O-rings" (geel pyltjies) gebruik (my R3 gekos vir 8 ) in plaas van dir BMW seals.  Hulle is R25 elk!  ???
Title: Re: Dakar Swingarm Bearing Mod
Post by: michnus on October 28, 2010, 10:51:00 am
yes ek's met jou, verstaan heeltemal reg.

Ek het weer bearings gebruik, nie copper bushes laat maak nie. The bushring is named on the fish

Maar wat jy nou se, het ek nie eerste reg verstaan op jou eerste thread nie. Jy se jy het nie meer bearings in die swing arm nie? Hoe gaan daar grease inkom tussen die bush en copper al het jy grease nipples, die tolerance is te tight? Gaan daar nie te veel wear wees nie?
Title: Re: Dakar Swingarm Bearing Mod
Post by: Jughead on October 28, 2010, 11:22:25 am
yes ek's met jou, verstaan heeltemal reg.

Ek het weer bearings gebruik, nie copper bushes laat maak nie. The bushring is named on the fish

Maar wat jy nou se, het ek nie eerste reg verstaan op jou eerste thread nie. Jy se jy het nie meer bearings in die swing arm nie? Hoe gaan daar grease inkom tussen die bush en copper al het jy grease nipples, die tolerance is te tight? Gaan daar nie te veel wear wees nie?

Nee, ek het nie meer bearing in die Swingarm nie.  Die gedeelte tussen die 2 Phosphor Bronze bushes is vol grease wat onder drukking is.  Dit is daaring vorseer met die greasegun.  Die enigste plek waar die grease kan uitkom is tussen die bush en die inner race.  Wat dit basies verhoed is dat water en kak nie daar kan inkom nie omdat die grease (Wat onder hoer druk is) probeer uitkom.  As dit wel begin wear, sal dit grease makliker kan uitkom, wat dan beteken dat die grease in die regte plek is, tussen die bush en die inner race.

Verskoon asb my afrikaan.  Ek is 'n soutie!  :biggrin:
Title: Re: Dakar Swingarm Bearing Mod
Post by: Jughead on October 28, 2010, 11:28:16 am
Still wanted to add.

Your bearings end up looking the way they do because water and sh1t gets into them.  With the grease nipples there I can make sure that

1. there is always grease on the bearings,
2. that water and crap cannot get in there because it is full of grease and
3. if water and crap did get in there it will be forced out the next time I force grease into the center.

This does not mean that I no longer remove the swingarm to check them.  I still do that, but I am minimizing the damage and wear on the races between services.
Title: Re: Dakar Swingarm Bearing Mod
Post by: RobC on October 28, 2010, 11:56:58 am
Great ideas and good tips here! :thumleft:
This grease nipple mod has also been done on some KLR's to great effect, will be doing mine next time I take the linkages apart for a checkup.
Title: Re: Dakar Swingarm Bearing Mod
Post by: lecap on October 29, 2010, 09:18:14 am
A few things:
O rings will work fine if you have grease nipples and use them. If you don''t fit grease nipples you should use shaft seals they give a much better seal and will stand up to wear from dust and grit on the outside for much longer
.
Regardless if you use o-rings or shaft seals you should provide a little void or equalisation hole (small, maybe 1.5mm) to allow the old grease and trapped air to get squirted out of the bearing. Ideally position the grease nipple very close to one seal and the void or bore very close to the other side of the bearing.

If you use "normal" single lip shaft sels it also helps to fit them "the wrong way around" means with the hollow side and spring (if any) facing outwards as the pressure will lift the sealing lip and allow trapped air & old grease to escape.

It's a bit of mechanical effort to nipple the KLR's rear swingarm pivot & cushion lever:
You'll have to drill & tap and crossdrill the bolts as well as cut grease grooves to allow the grrease from the cross bore to the holes. Make the grooves shallow and nicely rounded (like with a 2mm radius shaped chisel and maybe 0.2mm deep as you don't want to create too much of a stress concentrator. You have to drill holes into the needle bearings inner races in a position that comes to rest above the grease groove in the bolt when fitted. Drilling the inner races ain't plain sailing as you have to use a diamond tipped drill bit thanks to them being case hardened.
The needle bearings supporting the two bolts holding the "dogbones" can more easily be supplied with grease from nipples fitted into the swingarm or cushion lever between the bearings. Consider making and fitting spacers between the two bearings to reduce the size of the void between them (=reducing the amount of grease it takes to fill them).
Last but not least you have to provide the grease escape routes as mentioned above.

Too much effort to make it worthwhile IMHO as I never experienced problems with the KLR's swingarm pivot once greased well and regreased every 20,000km (of course no pressure washer attacks).
Title: Re: Dakar Swingarm Bearing Mod
Post by: RobC on October 29, 2010, 09:29:58 am

Too much effort to make it worthwhile IMHO as I never experienced problems with the KLR's swingarm pivot once greased well and regreased every 20,000km (of course no pressure washer attacks).
Thanks. After reading that... toss that idea! Spend the time and money on a ride! :imaposer:
Much more fun spending quality time stripping down the bike suspension every 20,000k for a good wash and lube. :thumleft:
About the only time it really needs a wash in any case! :imaposer:
Title: Re: Dakar Swingarm Bearing Mod
Post by: lecap on October 30, 2010, 08:54:50 am
Jy praat nou van die part met die rooi pyltjie?  Dit is die "Inner Race"

Ek het die bearings vervang met bushes, die groen pyltjies.

Ek het ook "O-rings" (geel pyltjies) gebruik (my R3 gekos vir 8 ) in plaas van dir BMW seals.  Hulle is R25 elk!  ???

Did you realize that your OEM seals also serve as some sort of thrust washers limiting axial movement of the swingarm?
Title: Re: Dakar Swingarm Bearing Mod
Post by: Jughead on October 31, 2010, 02:23:27 pm
Did you realize that your OEM seals also serve as some sort of thrust washers limiting axial movement of the swingarm?

No, I didn't realize that Lecap.  What disadvantages would there be to using rubber O-rings instead of the spongy foam-like OEM seals?
Title: Re: Dakar Swingarm Bearing Mod
Post by: the_BOBNOB on October 31, 2010, 02:49:00 pm
Did you realize that your OEM seals also serve as some sort of thrust washers limiting axial movement of the swingarm?

No, I didn't realize that Lecap.  What disadvantages would there be to using rubber O-rings instead of the spongy foam-like OEM seals?

if everything is machined to be a tight fit i cant see it being much of a problrm  :-\
Title: Re: Dakar Swingarm Bearing Mod
Post by: lecap on November 01, 2010, 07:45:01 am
Did you realize that your OEM seals also serve as some sort of thrust washers limiting axial movement of the swingarm?

No, I didn't realize that Lecap.  What disadvantages would there be to using rubber O-rings instead of the spongy foam-like OEM seals?

Sorry I was thinking Jap. bikes which actually do have thrust washers / thrust caps being part of the swingarm bearings or bearing seals. The Dakkie swingarm is supported laterally by the lip of the inner race and the seal.

Re. heating the swingarm to replace the bearings: Heating the F650GS swingarm will only help to burn your fingers. The difference between the thermal expansion coefficients of the swingarm (low carbon low alloy steel thermal expansion coefficient α around 11 x 10^-6/C) and the outer race of the needle bearing (high carbon steel α = 10.8 x 10^-6/C) is basically zilch. Different story with alli swingarms. α = 23 x 10^-6/C
Title: Re: Dakar Swingarm Bearing Mod
Post by: michnus on November 01, 2010, 08:25:27 am
Why would BMW mention it in their workshop manual heating the bearing seat to 100degrees if it is bs, or did they just mention it to make up billable time?
The new bearings went into the bearing seat with very little force after heating the bearing seat up.
The shaft seals can not act as thrust washer they are way to soft for it.

Tell me this. Took the swing arm out and is not able to get it back in with the black plastic caps that must go on the outside of the swing arm. I took the bushes out and fit them into the space where the swing arm must fit and the bushes only fit with zero space for the plastic washers. How de hell can a frame "close up" after removing the swing arm?
Title: Re: Dakar Swingarm Bearing Mod
Post by: RobC on November 01, 2010, 08:32:23 am
LeCap... fitting bearings by heating up the part that the bearing fit's into works on all kinds of metals, more so with Ali, less with steel. The big trick is to freeze/cool the bearing as well. I have fitted bearings using this method where the expansion was sufficient for the cool bearing to slip in with no effort at all. Once the part and bearing reach ambient they cannot be budged without using a persuasion tool of some sort.
Heating to remove is another story, especially if the bearing/part are steel... :mwink:
Title: Re: Dakar Swingarm Bearing Mod
Post by: Jughead on November 01, 2010, 08:44:06 am
Tell me this. Took the swing arm out and is not able to get it back in with the black plastic caps that must go on the outside of the swing arm. I took the bushes out and fit them into the space where the swing arm must fit and the bushes only fit with zero space for the plastic washers. How de hell can a frame "close up" after removing the swing arm?

O donner!  Michnus, you broke it!!   :imaposer:

Just loosen the bolt that holds the lower frame, the one below the motor that the sidestand attaches to.  It tends to clamp the frame together.  Just remember to tighten in again afterwards.
Title: Re: Dakar Swingarm Bearing Mod
Post by: michnus on November 01, 2010, 08:52:44 am
don't' laugh I are expert at stripping stuff , getting them together is where I f-up the best, most of the times the bike get towed away   :imaposer:
Title: Re: Dakar Swingarm Bearing Mod
Post by: Jughead on November 01, 2010, 11:38:45 am
don't' laugh I are expert at stripping stuff , getting them together is where I f-up the best, most of the times the bike get towed away   :imaposer:

Are these the same bushes you took out or new ones.  If they are new ones, check to see if they're the same length as the old ones.
Title: Re: Dakar Swingarm Bearing Mod
Post by: michnus on November 01, 2010, 12:10:42 pm
Same old bushes still waiting for the new ones.
Title: Re: Dakar Swingarm Bearing Mod
Post by: lecap on November 01, 2010, 12:33:35 pm
The shaft seals can not act as thrust washer they are way to soft for it.

...with the black plastic caps that must go on the outside of the swing arm...

I was wondering a bit about the setup but yes if there is caps on the outside of the swingarm pivot bearings then they will work as thrust washers. Didn't see them in your piccies and thought they weren't there :)

And yes of course heating the steel bearing seat and fitting a cold bearing works although you have to be very quick. I was referring to disassembly.
Still no comparsion to a bearing fitted with a press seat into aluminium. Stick it into your oven at 160C and it will just plop out :D

The story with an engine mounting bolt pinching the swingarm or suspension lever happens on plenty of bikes (KLR for example).
Title: Re: Dakar Swingarm Bearing Mod
Post by: Jughead on November 01, 2010, 12:46:27 pm
The story with an engine mounting bolt pinching the swingarm or suspension lever happens on plenty of bikes (KLR for example).

The lower bolt is not the engine mounting bolt on the Dakar.  The engine mounting bolt is the same as the swingarm bolt, the one that the bearings sit on.  The one I was referring to is the one for the frame below the engine.
Title: Re: Dakar Swingarm Bearing Mod
Post by: Aquatic on November 14, 2011, 03:31:26 pm
Hey Jughead

How are your bushes holding up?

I'm busy  doing a strip, clean and rebuild on my 2001 Dakar.

Some questions for you.
1. How much play did you have between the bolts and inner races? I have play in the whole linkage system that adds up to about 10mm at the end of the swing arm.
2. Did you check all the other bearings in the linkage system? All my inner races but 1 are stuffed >:( >:(
3. In your opinion would adding grease nipples to a bearing setup work or not?

Cheers
Title: Re: Dakar Swingarm Bearing Mod
Post by: Berty77 on November 14, 2011, 07:06:49 pm
Add Q20  ;D
Title: Re: Dakar Swingarm Bearing Mod
Post by: lecap on November 15, 2011, 08:53:08 am
Hey Jughead

How are your bushes holding up?

I'm busy  doing a strip, clean and rebuild on my 2001 Dakar.

Some questions for you.
1. How much play did you have between the bolts and inner races? I have play in the whole linkage system that adds up to about 10mm at the end of the swing arm.
2. Did you check all the other bearings in the linkage system? All my inner races but 1 are stuffed >:( >:(
3. In your opinion would adding grease nipples to a bearing setup work or not?

Cheers
1: Waaaay too much. Whilst you have a little bit of play in the diurection of suspension travel on some bikes (Yamaha XT600 for example) it should not exceed 2 or 3 mm measured on the rear wheel axle. If you have a lot of play it points at the needle bearings being poked. Make suer all bolts in the linkage are tightened when checking for play.
3: Grease nipples are a good idea but rather difficult to realise: You will have to find space for the  nipples (out of the way but still accessible for the grease gun), machine an access path from the grease nipple to the bearing. You ideally have one grease nipple per bearing and make sure the grease enters from one side and can escape through a pressure relief bore on the other side of the bearing.

Greasing the bearings through the swingarm pivot axle & bolts is tricky since it requires a lot of machining of bores & crossbores (including drilling inner bearing races) & grooves. Consideration has to be given to a reduction of the bolts shear strength.

If you grease the bearings on a new bike and disassemble, clean and grease every 40,000km or so the bearings usually last a lifetime. (At least in my KLR's / DR's) Never kept the F650's long enough for shite like that to happen ::)
Title: Re: Dakar Swingarm Bearing Mod
Post by: Aquatic on November 15, 2011, 09:40:50 am
thanks J

what about grease nipples between the 2 bearings as Jughead did with his bushes? The roller bearing cages do have a gap to the inner race. So the grease would travel from the centre outwards through the bearing.
Making a bolt with a hole down the middle is an option. Albeit a dear one.

The free play is an accumulation of the play between the bolts an inner races through the linkage system. Nothing seems worn, just a poor fit right from the start. I might look into aircraft grade bolts that have a h7 tolerance on the shaft.
The bearing races don't seem worn as far as I can feel, but they are rusted and pitted where the rollers run.
Will have to get some 4140 or equivilent turned, hardened and cylindrical ground.

Title: Re: Dakar Swingarm Bearing Mod
Post by: lecap on November 16, 2011, 09:48:33 am
Play between bolts and inner races does not play a role since it's eliminated as soon as you torque the bolts. I'd stay away from closely fitting bolts anyway since the play between the bolt and the inner race is essential for disassembly after a year or four. Best greased liberally since inner races love to rust onto the bolts even if the initial fit was rather loose. For illustration try to remove the bolt holding the suspension lever in the frame of a KLR which was never serviced properly. ::)

Are you shure it's worth to go through the process of machining, heat treating and grinding some carbon steel chunks instead of just buying OEM inner races?
Title: Re: Dakar Swingarm Bearing Mod
Post by: Jughead on February 13, 2015, 12:19:01 pm
Hey Jughead

How are your bushes holding up?

I'm busy  doing a strip, clean and rebuild on my 2001 Dakar.

Some questions for you.
1. How much play did you have between the bolts and inner races? I have play in the whole linkage system that adds up to about 10mm at the end of the swing arm.
2. Did you check all the other bearings in the linkage system? All my inner races but 1 are stuffed >:( >:(
3. In your opinion would adding grease nipples to a bearing setup work or not?

Cheers

Here's an update.  I sold this Dakar 4 years ago, but it still appears in my shop for it's regular services.

Took the swingarm apart at the last service (Early Jan 2015) and all bushes still look like the day I fitted them.

Re-greased them via the grease nipples and ready to go for another 4 years.
Title: Re: Dakar Swingarm Bearing Mod
Post by: Lem on February 13, 2015, 12:29:30 pm
Thanks  :thumleft:

learnt a lot here, as I also have a bit of up n down play on my swingarm I'd like to sort out
Title: Re: Dakar Swingarm Bearing Mod
Post by: Aquatic on February 13, 2015, 02:50:26 pm
Excellent Squire


Hey Jughead

How are your bushes holding up?

I'm busy  doing a strip, clean and rebuild on my 2001 Dakar.

Some questions for you.
1. How much play did you have between the bolts and inner races? I have play in the whole linkage system that adds up to about 10mm at the end of the swing arm.
2. Did you check all the other bearings in the linkage system? All my inner races but 1 are stuffed >:( >:(
3. In your opinion would adding grease nipples to a bearing setup work or not?

Cheers

Here's an update.  I sold this Dakar 4 years ago, but it still appears in my shop for it's regular services.

Took the swingarm apart at the last service (Early Jan 2015) and all bushes still look like the day I fitted them.

Re-greased them via the grease nipples and ready to go for another 4 years.